Leaf pack free. I found that vice-grips also work well for compressing the top leaves, in addition to c-clamps. I also experiemented with a ratchet strap to pull the top three leaves towards the chassis to allow for unough space to fit the new AAL, overload leaf and long-ass bolt that needs to go through all of them. Ratchet strap was the ticket for me. I couldnt get enough space without it.

The AAL in and lined up

Secured

Sawzall to fit the factory bump stop back on... I still need to get taller bump stops to prevent shock bottoming. I'll be taking it easy until then.

Plenty of threads to spare re-using the stock U-bolts.

Stacked some old shock bushings and used longer bolt to bring the brake line bracket up a couple inches.

After: Ground to fender flare driver side 40"

After: Ground to fender flare passenger 40 1/4"

Done

I got rake. Next weekend is 5100's and 885s with dvr trim packer for the front to replace the 1" daystar spaces and TRD Billys I installed long time ago.

What do I need to do to correct it? What damage am I risking with it being damn near flush to the retainer?

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I think when the leaf pack flexes, that new leaf you put it could hit the retainer clips which could break the clips and/or affect the way the leaf pack is supposed to work.

The deaver tsb aal is 28" long I believe, with the hole in the center of the leaf (according to jflan). Just make sure they sent you the right one, or you could probably just cut 1-1/2 off each end since you have the desired lift that you wanted. I talked to a few mechanics and guys on here and it doesn't seem to be a problem to cut them, just don't use a torch or anything else that will apply heat to the leaf.

The AAL I received did not have a centered hole. I did not measure the length before installing. I sent a sperate note to Toytec direclty for clarification. I'll post response.

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I think most people put the longer end facing toward the back of the truck if the hole is not centered, but after searching a bit it look like people have put them in the other way around with no problems.

Thanks all for your responses bringing this issue to my attention. I just got of the phone with Toytec - they accidentally sent the non-TSB AAL. The correct TSB AAL is on the way.

For future reference - TSB AALs are shorter in length and the hole for centering pin is centered lengthwise on the AAL. non-TSB are longer and hole for centering pin is not centered lengthwise and long end should always go to the rear of the truck.

Other notes - part number for non-TSB ends in 70.. it can be seen in my pictures. Part number for TSB AAL ends in 73.

Anyone doing an AAL should double check these things before turning the first wrench.

Thanks all for your responses bringing this issue to my attention. I just got of the phone with Toytec - they accidentally sent the non-TSB AAL. The correct TSB AAL is on the way.

For future reference - TSB AALs are shorter in length and the hole for centering pin is centered lengthwise on the AAL. non-TSB are longer and hole for centering pin is not centered lengthwise and long end should always go to the rear of the truck.

Other notes - part number for non-TSB ends in 70.. it can be seen in my pictures. Part number for TSB AAL ends in 73.

Anyone doing an AAL should double check these things before turning the first wrench.

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Glad you got it sorted.

For reference :
My local spring shop said that 1-1/2" clearance from AAL end to spring retainer clip would be "more than enough" clearance.
One of the members here that does a lot of spring work said that even if they were touching, the clip and the AAL move out at roughly the same rate.
As a bare minimum, I would shoot for 1" clearance.

OP, when finished, please report your before and after hub-to-fenderwell dimensions so we can log them into the database.
(I'm kind of curious as to what your current non-TSB AAL + TSB pack dimension is, as well.)

i intend to switch to the correct AAL once I get it, however, I must say, I like the lift, rake and the ride I'm getting with the wrong AAL kit... I just dont want to break anything from running it. I havent put any load in the back since doing it, but I did intentionally get into some flex situations forcing compression and extension. Seems to be working - flexes good both ways and doesnt appear to be causing any damage to the leaf retainer or the leaf pack... at least not visibly. To be continued...

i intend to switch to the correct AAL once I get it, however, I must say, I like the lift, rake and the ride I'm getting with the wrong AAL kit... I just dont want to break anything from running it. I havent put any load in the back since doing it, but I did intentionally get into some flex situations forcing compression and extension. Seems to be working - flexes good both ways and doesnt appear to be causing any damage to the leaf retainer or the leaf pack... at least not visibly. To be continued...

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What is the dimension from center of axle to top of wheel well opening ?

I just cut my aal's from 36" to 30" tonight and got them installed. I was at 21-1/2" hub to fender, now at 23-1/2" (with a cap). Install was easy except for trying to line the holes back up.

Add a leaf in the back, 5100's with ome 885's up front and the truck drives like a dream, even without a wheel alignment yet. No vibes, no wandering. New wheels and duratracs next.

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Did your aal originally have rub/friction pads on the ends? Seriously i'm considering cutting mine also, but only around 1 1/2 on the rear to get off the retainer. My replacement aal will be here tomorrow. I'll decide then.

No, the leafs they sent me didn't have anything on them. I noticed the existing leaf pack had very thin metal shims between them at center, so on the new aal I added a thin teflon shim as well (not sure if this is necessary). At 30" the aal is now within 1-1/2 of the retainers. If you do cut, just make sure you file down the sharp edge so it doesn't dig into the leaf above it.

Lots of deliveries today. Correct 1.5 AAL for TSB from toytec, 885's and trim packer from DSM, and a return shipping label for the non-tsb AAL (guess I wont be cutting the AAL i have on the truck). The agenda for Saturday is set.